Fan filter unit with integrated heater

ABSTRACT

A fan filter unit with an integrated heater system includes a housing comprising an air intake and an air outlet; a blower motor mounted within the housing and downstream of the air intake; a heater mounted within the housing and downstream of the blower motor; and an air filter mounted within the housing. In some cases, the system further includes an inner housing mounted to a top of an inside portion of the housing, the inner housing having an inner housing air outlet, where both the blower motor is mounted within the inner housing and the heater is mounted within the inner housing. In some of such cases, the air intake and the air outlet are positioned to direct an air flow vertically and the inner housing air outlet is positioned to direct an air flow horizontally.

BACKGROUND

There is a need for additional pharmaceutical cleanroom space, as well as cleanroom (and/or laboratory) infrastructure for a range of bioprocessing and biomanufacturing applications. However, additional space for these cleanrooms (and/or laboratories) may take years to build due to the complexity of the requirements for these facilities. Furthermore, there may not be room anywhere close to existing cleanroom (and/or laboratory) facilities to build new space. Therefore, mobile (e.g., towable) and modular (e.g., prefabricated and designed for permanent and/or semi-permanent placement) cleanrooms have become increasingly popular.

Due to the limits set on the size of mobile and modular cleanroom space (e.g., due to limitations in shipping size and other factors), space within mobile and modular laboratories is meticulously planned out and utilized to the fullest extent possible. One critical requirement for mobile and/or modular cleanrooms is that the air brought in from the outside and/or released from the inside of the mobile and/or modular laboratory to the outside and/or recirculated air is filtered to remove any contaminants. Therefore, fan filter units are used to remove contaminants from the air, which take up space in the mobile and/or modular cleanrooms.

Another critical requirement for mobile and modular cleanroom space is that the humidity of that air must be controlled and be maintained within very specific parameters. Indeed, depending on the climate in which the mobile and/or modular cleanrooms are placed, humidity control is a major issue. To control and/or reduce humidity, air conditioning units are used. However, this can leave the temperature within the mobile and/or modular cleanrooms at an uncomfortable temperature level (e.g., too cold) for workers utilizing the mobile and/or modular cleanrooms. Therefore, heating units are added to warm the temperature of the cool, dehumidified air, which take up more space in the mobile and/or modular cleanrooms.

BRIEF SUMMARY

Fan filter units with an integrated heater are provided. By integrating a heater into a traditional fan filter unit used in mobile and/or modular cleanrooms and/or laboratories, the overall amount of space required for the fan filter unit and the heater is reduced. Indeed, fan filter units with an integrated heater provided herein are designed to be placed within the ceiling, or even a wall, allowing for more space that can be utilized for other functions that would normally be occupied by the fan filter unit and/or the heater unit, which is even more critical in cleanrooms and/or laboratories that have limited space such as mobile and/or modular cleanrooms and/or laboratories. The placement of the heater (e.g., downstream of the blower motor) reduces overheating and/or tripping of the blower motor. The placement of the air filter (e.g., proximal/flush with the ceiling) allows for ceiling-side access to the components within the fan filter unit with the integrated heater, including but not limited to, the blower motor, heater, and control panel.

Advantageously, through certain of the described configurations, individual rooms under the same plenum can have their own humidity and temperature control without the need for any extra space-using air ducts. This is especially useful in rooms that require different levels of personal protective equipment, which can affect what temperature and humidity combination is comfortable, enhancing safety and promoting safe work habits such as not dropping masks when uncomfortably warm. Furthermore, not only is the fan filter unit with an integrated heater useful in mobile and modular cleanrooms and/or laboratories, it is also useful in any application in which a heater and a filter are needed, especially those in which space is limited. The inventor searched for many years to find a solution that included the above advantages, but never found any products that included these advantages.

In some embodiments, a fan filter unit with an integrated heater system includes a housing comprising an air intake and an air outlet; a blower motor mounted within the housing and downstream of the air intake; a heater mounted within the housing and downstream of the blower motor; and an air filter mounted within the housing.

In some cases, when the blower motor is in operation, the blower motor generates an air flow from the air intake to the air outlet. In some cases, the blower motor comprises a backward curved centrifugal fan. In some cases, the heater is positioned below the blower motor. In some cases, a vertical height of the housing is less than or equal to sixteen inches. In some cases, the system is configured to receive dehumidified air from an air conditioning system that is upstream of the system. In some cases, the system is further configured to be mounted within a roof of a modular building. In some cases, the air filter is downstream of the heater. In some cases, the system further includes a temperature sensor and a fan filter unit (FFU) controller configured to control an ambient temperature inside a space based on temperature readings from the temperature sensor and input of a desired temperature. In some cases, the system further includes a humidity sensor and an FFU controller configured to control relative humidity inside a space based on humidity readings from the humidity sensor and input of a desired humidity.

In some cases, the system further includes an inner housing mounted to a top of an inside portion of the housing, the inner housing having an inner housing air outlet. In some cases, the blower motor is mounted within the inner housing. In some cases, the heater is mounted within the inner housing. In some cases, the air intake and the air outlet are positioned to direct an air flow vertically and the inner housing air outlet is positioned to direct an air flow horizontally. In some cases, when the blower motor is in operation, the blower motor generates an air flow from the air intake, through the inner housing air outlet, and out of the air outlet.

In some embodiments, a fan filter unit with an integrated heater system includes an outer housing comprising an outer housing air intake and an outer housing air outlet; an inner housing mounted to a top of an inside portion of the outer housing, the inner housing having an inner housing air outlet; a blower motor mounted within the inner housing and proximally to the outer housing air intake, wherein when the blower motor is in operation, the blower motor generates an air flow from the outer housing air intake, through the inner housing air outlet, and out the outer housing air outlet; a heater mounted within the inner housing and distally to the outer housing air intake; and an air filter mounted within the outer housing.

In some cases, the outer housing air intake and the outer housing air outlet are positioned to direct the air flow vertically and the inner housing air outlet is positioned to direct the air flow horizontally. In some cases, the blower motor comprises a backward curved centrifugal fan. In some cases, a vertical height of the outer housing is less than or equal to sixteen inches. In some cases, the system is configured to be mounted within a roof of a modular building. In some cases, the air filter is mounted proximally to the outer housing air outlet.

In some embodiments, a fan filter unit with an integrated heater system includes a housing comprising an air intake and an air outlet, wherein a vertical height of the housing is less than or equal to sixteen inches; a blower motor mounted within the housing and downstream of the air intake; a heater mounted within the housing and downstream of the blower motor; and an air filter mounted within the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a diagram of a fan filter unit with an integrated heater.

FIGS. 2A-2F illustrate various views of a fan filter with integrated heater.

FIG. 3 illustrates a representational diagram of a computing device operating on an application management service for controlling at least one fan filter unit with an integrated heater.

DETAILED DESCRIPTION

Fan filter units with an integrated heater are provided. By integrating a heater into a traditional fan filter unit used in mobile and/or modular cleanrooms and/or laboratories, the overall amount of space required for the fan filter unit and the heater is reduced. Indeed, fan filter units with an integrated heater provided herein are designed to be placed within the ceiling, or even a wall, allowing for more space that can be utilized for other functions that would normally be occupied by the fan filter unit and/or the heater unit, which is even more critical in cleanrooms and/or laboratories that have limited space such as mobile and/or modular cleanrooms and/or laboratories. The placement of the heater (e.g., downstream of the blower motor) reduces overheating and/or tripping of the blower motor. The placement of the air filter (e.g., proximal/flush with the ceiling) allows for ceiling-side access to the components within the fan filter unit with the integrated heater, including but not limited to, the blower motor, heater, and control panel.

As used herein, downstream refers to a position of a first object in relation to a position of a second object within an air flow, wherein the position of the first object is downwind of the position of the second (e.g., reference) object within the airflow.

As used herein, upstream refers to a position of a first object in relation to a position of a second object within an air flow, wherein the position of the first object is upwind of the position of the second (e.g., reference) object within the airflow.

FIG. 1 illustrates a diagram of a fan filter unit with an integrated heater. Referring to FIG. 1, a fan filter unit with an integrated heater 100 includes a housing 102 having an air intake 104 and an air outlet 106. The fan filter unit with the integrated heater 100 further includes a blower motor 110, a heater, 120, and an air filter 130. The blower motor 110 is mounted within the housing 102 and is downstream of the air intake 104. The heater 120 is mounted within the housing 102 and downstream of the blower motor 110. The air filter 130 is mounted within the housing.

The housing has a vertical height (H). In some cases, the housing 102 has a vertical height (H) of less than or equal to sixteen inches. In some cases, the housing 102 has a vertical height (H) of less than or equal to fifteen inches.

In some cases, such as illustrated in FIG. 1, the air filter 130 is downstream of the heater 120. In some cases, the air filter 130 is upstream of the heater 120.

When the blower motor 110 is in operation, the blower motor 110 generates an air flow from the air intake 104 to the air outlet 106, through the air filter 130 and the heater 120. In some cases, the blower motor 110 is a backward curved centrifugal fan.

The fan filter unit with an integrated heater 100 can further include a temperature sensor 140, a humidity sensor 144 and a FFU controller 142 configured to control temperature and relative humidity inside a space by causing the heater 120 and/or the blower motor 110 to operate based on temperature readings from the temperature sensor 140, humidity readings from the humidity sensor 144, and user input and/or a pre-programmed desired humidity for that space. It should be understood that the positioning of the temperature sensor 140, the FFU controller 142, and the humidity sensor 144 in FIG. 1 is merely for illustrative purposes, and those components can be positioned anywhere within the fan filter unit with the integrated heater 100 to affect the desired outcome (e.g., temperature readings from the temperature sensor 140, humidity readings from the humidity sensor 144, and control of the blower motor 110 from the FFU controller 142).

In some cases, the fan filter unit with integrated heater 100 does not include the humidity sensor 144 and instead includes the temperature sensor 140 and the fan filter unit (FFU) controller 142, where the FFU controller 142 is configured to control an ambient temperature inside a space (e.g., a modular and/or mobile clean room) by causing the heater 120 and/or the blower motor 110 to operate based on temperature readings from the temperature sensor 140 and user input and/or a pre-programmed desired temperature (e.g., from a user/worker in the modular and/or mobile clean room) indicating temperature for that space.

In some cases, the fan filter unit with integrated heater 100 does not include the temperature sensor 140 and instead includes the humidity sensor 144 and the FFU controller 142, where the FFU controller 142 is configured to control relative humidity inside a space by causing the heater 120 and/or the blower motor 110 to operate based on humidity readings from the humidity sensor 144 and user input and/or a pre-programmed desired humidity for that space.

FIGS. 2A-2F illustrate various views of a fan filter with integrated heater. FIG. 2A illustrates a side-angle view of a fan filter unit with an integrated heater; FIG. 2B illustrates a side view of a fan filter unit with an integrated heater; FIG. 2C illustrates a longitudinal cross-sectional view of a fan filter unit with an integrated heater; FIG. 2D illustrates air flow through a longitudinal cross-sectional view of a fan filter unit with an integrated heater; FIG. 2E illustrates a top view of the fan filter unit with an integrated heater; and FIG. 2F illustrates a lateral cross-sectional view of a fan filter unit with an integrated heater.

Referring to FIG. 2A, a fan filter unit with an integrated heater 200 includes an outer housing 202. In this example, the outer housing 202 is a cuboid shape, however, in other cases as explained below, other shapes may be used. In this example, the outer housing 202 includes an A side 204 and a B side 206, which is on a plane perpendicular to the A side 204.

Referring to FIG. 2B, a side view of the A side 204 is shown with a cross-sectional line A-A′, reflecting the longitudinal cross-sectional view illustrated in FIGS. 2C and 2D.

Referring to FIG. 2C, the fan filter unit with integrated heater 200 includes an inner housing 222, a blower motor 230, a heater 240, and an air filter 250 within the outer housing 202. The outer housing 202 includes an outer housing air intake 208 and an outer housing air outlet 210. The inner housing 222 is mounted to a top 216 of an inside portion 214 of the outer housing 202 and includes one or more inner housing air outlets 224.

The blower motor 230 is mounted within the inner housing 222 and proximal to the outer housing air intake 208. The heater 240 is mounted within the inner housing 222 and distal to the outer housing air intake 208. The air filter 250 is mounted within the outer housing 202 (e.g., between the inner housing air outlet 224 and the outer housing air outlet 210).

Referring to FIG. 2D, when the blower motor 230 is in operation, the blower motor 230 generates an air flow from the outer housing air intake 208, through the inner housing air outlet 224, and out the outer housing air outlet 210. In other words, the air flow generated by the blower motor 230 (e.g., when the blower motor 230 is in operation) passes the following components of the fan filter unit with an integrated heater 200 in sequential order: the outer housing air intake 208, the blower motor 230, the heater 240, the inner housing air outlet 224, the air filter 250, and the outer housing air outlet 210. In some cases, the sequential order in changed by positioning the air filter 250 between the blower motor 230 and the heater 240 or upstream of the blower motor 230.

In some cases, the outer housing air intake 208 is positioned to direct the air flow vertically. In some cases, the outer housing air outlet 210 is positioned to direct the air flow vertically. In some cases, the inner housing air outlet 224 is positioned to direct the air flow horizontally (e.g., over the heater 240). In this way, the fan filter unit with the integrated heater 200 can save vertical height (e.g., so the fan filter unit with the integrated heater 200 can be mounted between a ceiling and a roof of a mobile and/or modular building, or even a conventionally constructed cleanroom facility) by moving the air flow horizontally from the blower motor 230 over the heater 240 before passing through the air filter 250, which provides an air flow that is filtered to the applicable cleanroom standards and is comfortable (e.g., warm enough) for workers. In other cases (e.g., in cases where a smaller blower motor 230 can be used and/or when there is more vertical height than normal between a roof and a ceiling of a mobile and/or modular building), the heater 240 is positioned below the blower motor 230.

In some cases, a control panel 252 (e.g., including a controller as described with respect to FIGS. 1 and 3) is mounted at a side 218 of the inside portion 214 of the outer housing 202. In some cases, the control panel 252 is mounted to the top 216 or a bottom 220 of the inside portion 214 of the outer housing 202.

In some cases, the air filter 250 may be positioned upstream of the blower motor 230 or in between the blower motor 230 and the heater 240. In some cases, the placement of the air filter 250 (e.g., proximal/flush with the ceiling) allows for ceiling-side access to the components within the fan filter unit with the integrated heater 200, including but not limited to, the blower motor 230, heater 240, and control panel 252. Indeed, this allows easy access for any maintenance, repair, and/or replacement of components while still applying with any applicable code (e.g., the National Electric Code).

Referring to FIG. 2E, a side view of the B side 206 is shown with a cross-sectional line B-B′, reflecting the lateral cross-sectional view illustrated in FIG. 2F. Referring to FIG. 2F, the blower motor 230 is mounted within the inner housing 222. The heater 240 is positioned within the inner housing 222 downstream (e.g., horizontally in a longitudinal direction) from the blower motor 230. The air filter 250 is positioned within the outer housing 202 (and outside of the inner housing 222) and downstream (e.g., vertically below) from the heater 240 and blower motor 230.

Referring to FIGS. 2A-2F, in some cases, the outer housing 202 has a vertical height (H) of less than or equal to sixteen inches (e.g., as illustrated in FIG. 1 and FIG. 2B). In some cases, the outer housing 202 has a vertical height (H) of less than or equal to fifteen inches. In some cases, the outer housing 202 has a longitudinal length (L) of less than or equal to forty-eight inches (e.g., as illustrated in FIGS. 2C and 2D). In some cases, the outer housing 202 has a lateral width (W) of less than or equal to twenty-four inches (e.g., as illustrated in FIG. 2E).

In some cases, the blower motor 230 may be a backward curved centrifugal fan. The blower motor 230 may also be (in addition to or separately) an electronically commutated motor (ECM). In some cases, the air filter 250 is a MERV 17 or 18 air filter. In some cases, the air filter is a MERV 19 or higher. In some cases, the air filter 250 is a HEPA air filter. In some cases, the air filter 250 is an ULPA air filter. It should be understood that the air filter 250 may be any suitable air filter that provides an acceptable level of reduction of contaminants from the air flow according to applicable standards and/or regulations. In some cases, the air filter 250 may include multiple air filters in series (e.g., a MERV 12 air filter followed by a MERV 17 air filter or higher downstream). In some cases, ultraviolet light may be incorporated to disinfect the internal components of the fan filter unit with the integrated heater 200.

Although FIGS. 2A-2F illustrate a fan filter unit with an integrated heater 200 that is in the shape of a cuboid, in other cases, different shapes may be used. For example, the fan filter unit with an integrated heater may be cylindrical, a pentagonal prism, a hexagonal prism, or the like to fit the space for which the fan filter unit with an integrated heater needs to fit for the intended use.

In any case, the fan filter unit with integrated heater includes a heater that is downstream of the blower motor and an air filter. In some cases, the fan filter unit with integrated heater is configured receive dehumidified air (e.g., from an air conditioner system that is upstream of the fan filter unit with the integrated heater). In some cases, the air is transferred from an air conditioning system to the fan filter unit with the integrated heater via a plenum above a ceiling in the room to which the airflow is dispersed. In some cases, the fan filter unit with the integrated heater is configured to be placed between a roof and a ceiling of a mobile and/or modular building (e.g., having a vertical height that is less than or equal to sixteen inches and dispersing the air flow vertically through the air outlet of the outer housing) by mounting the (outer) housing to the roof and/or ceiling (or structure in and around the roof and/or ceiling). In some cases, the (outer) housing can be mounted via screws, nails, adhesive, tape, foam insulation, and/or any other means that meets applicable building standards. In these cases, the fan filter unit with the integrated heater can warm the dehumidified (and potentially overcooled) air for comfort of workers in the building, while also filtering that air of contaminants to the applicable cleanroom standards for air.

FIG. 3 illustrates a representational diagram of a computing device for controlling at least one fan filter unit with an integrated heater. A fan filter unit with an integrated heater (e.g., any of the fan filter units with integrated heater described with respect to FIGS. 1-2F above) can include a computing device 300. In some cases, the computing device 300 may be referred to as an FFU controller and/or blower motor controller. The computing device 300 may be disposed in the control panel 252 described with respect to FIGS. 2C and 2D. The computing device 300 may be implemented as part of a building management system(s) and/or a building automation system(s).

Referring to FIG. 3, computing device 300 can include a processor 310, storage 320, heater interface 330, optional blower motor interface 340, user interface 350, and a communications system 360 coupled, for example, via a system bus 370. Processor 310 can include one or more of any suitable processing devices (“processors”), such as a microprocessor, central processing unit (CPU), graphics processing unit (GPU), field programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), logic circuits, and state machines. Storage 320 can include any suitable storage media that can store instructions 322 for controlling operation of the fan filter unit with an integrated heater. The instructions 322 providing the operations may be carried out as part of an application(s) for building management systems and/or building automation systems, including application(s) used for any widely used protocols, including BACnet (or vendor-specific platforms). As used herein “storage media” do not consist of transitory, propagating waves. Instead, “storage media” refers to non-transitory media.

Communications system 360 can include a network interface for coupling to the Internet or cellular service (e.g., for communicating with a service tied to a mobile application on a mobile device) and/or a short range interface (near field, wide band, or other common communication protocols) that can be used to communicate wirelessly with nearby devices. In some cases, sensors (e.g., a temperature sensor and/or humidity sensor as described above with respect to FIG. 1) may also be in communication with the computing device 300 via an interface associated with the communications system 360 or via direct interfaces for those sensors (or generic I/O interfaces such as USB or firewire).

The user interface 350 can include a touch screen through which a user may input information and settings for certain operations carried out by the processor 310 executing the instructions 322 stored on the storage 320.

The instructions 322 stored on the storage 320 are executed by the processor 310 to carry out control operations for the fan filter unit with an integrated heater. The instructions 322 can cause the device to turn the blower motor on, off, and/or to different volumetric flow rates. The instructions 322 can also include adjusting the settings on the heater and/or blower motor that correspond to a desired temperature of the air flow that is discharged from the air outlet (e.g., as described above with respect to FIGS. 1-2F). The instructions 322 can also include adjusting the setting on the heater and/or blower motor that correspond to a desired humidity of the air flow that is discharged from the air outlet (e.g., as described above with respect to FIGS. 1-2F). In some cases, instead of instructions 322 stored on the storage 320, the operations are performed entirely in hardware.

Advantageously, as described herein, individual rooms under the same plenum can have their own humidity and temperature control without the need for any extra space-using air ducts. This is especially useful in rooms that require different levels of personal protective equipment, which can affect what temperature and humidity combination is comfortable, enhancing safety and promoting safe work habits such as not dropping masks when uncomfortably warm. Furthermore, not only is the fan filter unit with an integrated heater useful in mobile and modular cleanrooms and/or laboratories, it is also useful in any application in which a heater and a filter are needed, especially those in which space is limited. The inventor searched for many years to find a solution that included the above advantages, but never found any products that included these advantages.

Although the subject matter has been described in language specific to structural features and/or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims. 

What is claimed is:
 1. A system comprising: a housing comprising an air intake and an air outlet; a blower motor mounted within the housing and downstream of the air intake; a heater mounted within the housing and downstream of the blower motor; and an air filter mounted within the housing.
 2. The system of claim 1, wherein when the blower motor is in operation, the blower motor generates an air flow from the air intake to the air outlet.
 3. The system of claim 1, further comprising an inner housing mounted to a top of an inside portion of the housing, the inner housing having an inner housing air outlet.
 4. The system of claim 3, wherein the blower motor is mounted within the inner housing.
 5. The system of claim 4, wherein the heater is mounted within the inner housing.
 6. The system of claim 3, wherein the air intake and the air outlet are positioned to direct an air flow vertically and the inner housing air outlet is positioned to direct an air flow horizontally.
 7. The system of claim 6, wherein when the blower motor is in operation, the blower motor generates an air flow from the air intake, through the inner housing air outlet, and out of the air outlet.
 8. The system of claim 1, wherein the blower motor comprises a backward curved centrifugal fan.
 9. The system of claim 1, wherein the heater is positioned below the blower motor.
 10. The system of claim 1, wherein a vertical height of the housing is less than or equal to sixteen inches.
 11. The system of claim 10, wherein the system is configured to receive dehumidified air from an air conditioning system that is upstream of the system.
 12. The system of claim 11, wherein the system is further configured to be mounted within a roof of a mobile or modular building.
 13. The system of claim 1, wherein the air filter is downstream of the heater.
 14. The system of claim 1, further comprising a temperature sensor and a fan filter unit (FFU) controller configured to control an ambient temperature inside a space based on temperature readings from the temperature sensor and input of a desired temperature.
 15. The system of claim 1, further comprising a humidity sensor and a fan filter unit (FFU) controller configured to control a relative humidity inside a space based on humidity readings from the humidity sensor and input of a desired humidity.
 16. A system comprising: an outer housing comprising an outer housing air intake and an outer housing air outlet; an inner housing mounted to a top of an inside portion of the outer housing, the inner housing having an inner housing air outlet; a blower motor mounted within the inner housing and proximal to the outer housing air intake, wherein when the blower motor is in operation, the blower motor generates an air flow from the outer housing air intake, through the inner housing air outlet, and out the outer housing air outlet; a heater mounted within the inner housing and distal to the outer housing air intake; and an air filter mounted within the outer housing.
 17. The system of claim 16, wherein the outer housing air intake and the outer housing air outlet are positioned to direct the air flow vertically and the inner housing air outlet is positioned to direct the air flow horizontally.
 18. The system of claim 16, wherein a vertical height of the outer housing is less than or equal to sixteen inches.
 19. The system of claim 16, wherein the air filter is mounted proximal to the outer housing air outlet.
 20. A system comprising: a housing comprising an air intake and an air outlet, wherein a vertical height of the housing is less than or equal to sixteen inches; a blower motor mounted within the housing and downstream of the air intake; a heater mounted within the housing and downstream of the blower motor; and an air filter mounted within the housing. 